蝶阀后管线腐蚀发生与发展机制研究

doi:10.11949/0438-1157.20221209

摘要/Abstract

摘要：

针对某石化厂蝶阀后管线异常减薄的问题，结合腐蚀分析、腐蚀实验和数值模拟，分析了管线异常减薄的原因，研究了腐蚀的发生与发展机制。样品的结构及成分通过扫描电镜（SEM）、X射线衍射（XRD）和能谱仪（EDS）及金相显微镜进行表征，并结合计算流体动力学（CFD）分析了流场参数对腐蚀过程的影响。结果表明，管线主要的失效原因是流动加速腐蚀。此外，基于速度边界层与壁面粗糙度之间的关系，将蝶阀后管线划分为三个不同的区域，并用示意图对不同区域腐蚀的发生与发展机制进行了解释。

关键词: 管线, 腐蚀, 计算流体力学, 电化学, 流动

Abstract:

Aiming at the abnormal thinning of the pipeline behind the butterfly valve in a petrochemical plant, combined with corrosion analysis, corrosion test and numerical simulation, the causes of abnormal thinning of the pipeline were analyzed, and the occurrence and development mechanism of corrosion were studied. The structure and composition of the samples were characterized by scanning electron microscope (SEM), X-ray diffraction (XRD), energy spectrometer (EDS) and metallographic microscope. The influence of flow field parameters on corrosion process was calculated and analyzed based on computational fluid dynamics (CFD). The results show that the main failure reason is flow accelerated corrosion. In addition, the pipeline behind the butterfly valve is divided into three different areas based on the relationship between velocity boundary layer and wall roughness, and the occurrence and development mechanism of corrosion in different areas are explained by schematic diagrams.

Key words: pipeline, corrosion, computational fluid dynamics, electrochemistry, flow

中图分类号:

TE 969

苏国庆, 张建文, 李彦. 蝶阀后管线腐蚀发生与发展机制研究[J]. 化工学报, 2022, 73(12): 5504-5516.

Guoqing SU, Jianwen ZHANG, Yan LI. Study on the occurrence and development mechanism of pipeline corrosion behind butterfly valve[J]. CIESC Journal, 2022, 73(12): 5504-5516.

图/表 22

图1 蝶阀结构和阀后管线壁面划分

Fig.1 Butterfly valve structure and pipe wall division

Table 2 Composition of conveying medium

组成	含量/%(mass)
H₂O	18
C₃	0.06
C₄	0.31
C₅	1.25
C₆	6.85
C₇	15.05
C₈	25.34
C₉	24.23
C₁₀	8.23
C₁₁	0.64
H₂S	0.0272
Cl^-	0.006

表2　输送介质组成

图2 样品实物图

Fig.2 Physical map of samples

图3 厚度分布

Fig.3 Thickness distribution

图4 样品扫描电镜图像

Fig.4 SEM images of samples

图5 样品能谱分析结果

Fig.5 EDS spectrums of samples

图6 样品XRD谱图

Fig.6 XRD patterns of samples

表3 304不锈钢试样化学成分

Table 3 Chemical composition of 304 stainless steel coupons

元素	含量/%(mass)
C	0.03
Mn	1.22
P	0.02
S	0.02
Si	0.31
Cr	18.90
Ni	9.10
Fe	70.4

图7 实验装置示意图

Fig.7 Schematic diagram of experimental device

图8 试样的宏观形貌

Fig.8 Morphology structure of specimen

图9 试样的微观形貌

Fig.9 Micromorphology of specimen

图10 蝶阀计算域及网格划分

Fig.10 Computational domain and mesh division of butterfly valve

表4 模拟的边界条件

Table 4 Simulated boundary conditions

参数	数值
入口流速/(m/s)	1.5
介质密度/(kg/m³)	790
介质黏度/cP	0.43
压力/MPa	0.15

图11 不同数量网格下左壁面的切应力分布

Fig.11 Wall shear distribution of left wall at different number of meshes

图12 截面位置示意图

Fig.12 Schematic diagram of section position

图13 不同截面的速度云图

Fig.13 Velocity nephogram of different sections

图14 不同截面的流线分布

Fig.14 Streamline distribution of different sections

图15 不同开度下的切应力分布

Fig.15 Wall shear distribution at different opening degrees

图16 不同壁面粗糙度下的切应力分布

Fig.16 Wall shear distribution at different wall roughness

表5 不同粗糙度下的流动类型

Table 5 Flow types at different roughness

e/mm	流动类型
0≤e≤0.08	水力光滑管
0.08<e<0.85	过渡区圆管
e≥0.85	完全粗糙管

图17 蝶阀后管线腐蚀发生与发展机制示意图

Fig.17 Schematic diagram of occurrence and development mechanism of pipeline corrosion behind butterfly valve

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